Enclosure undercarriage support system

ABSTRACT

In one exemplary embodiment, a method of constructing an enclosure using an undercarriage support system comprises: providing the undercarriage support system for supporting the enclosure during one or more stages of construction, the undercarriage support system comprising a plurality of modular enclosure support components and a plurality of motive supports for facilitating movement of the undercarriage support system; interconnecting ends of the modular enclosure support components via respective inter-component end ports; assembling the interconnected modular enclosure support components such that the undercarriage support system exhibits a degree of structural rigidity sufficient to support an entire weight of the enclosure during one or more stages of construction; and executing one or more stages of enclosure construction while at least a portion of the enclosure is supported by the undercarriage support system and while the undercarriage support system and the enclosure supported thereon are moveable via the plurality of motive supports.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/093,032 filed Aug. 29, 2008 (HUR 0005 MA).

BACKGROUND

Various industries rely upon fabrication of enclosures for use as sub-assemblies or end-products. One such example is the design and manufacture of enclosures of varying materials and sizes to enclose components that collectively are used to generate electricity or other energy outputs. Several factors are driving demand for auxiliary power systems that are commonly used for industrial, construction, mining, oil & gas exploration, and commercial applications. These power systems typically utilize a diesel engine that when combined with other electrical components are used to generate electricity. The resulting electrical output is then used for both prime (primary source) and backup (redundant source) power. For industrial applications this is used to support either prime or backup electricity within factories, for construction, mining, and oil & gas applications these are typically used to generate prime power for the equipment given the locations are too distant for connection to the municipal electrical grid; for commercial applications these are typically used for backup power for the electrical systems should the municipal electrical grid lose power due to a storm, natural disasters, sabotage, etc.

The enclosures are typically assembled from components largely fabricated from within the same manufacturing facility where resulting specifications are engineered to comply with pre-determined constraints such as outside dimensions, air flow requirements within the enclosure, space requirements within the enclosure for internal components, etc. The enclosures are typically assembled by several individuals who work together to fit the enclosure together. The enclosure remains in the location from which assembly started until time that the manufacturer chooses to move the enclosure. This is often done via an overhead crane or pushing/pulling via forklift. This move can be expensive in terms of utilizing an expensive overhead crane, and in terms of the added risk of gravity damaging what can be a very expensive enclosure should it fall from the overhead crane. Though using a forklift to push or pull the enclosure by dragging it on the flooring may not be as expensive to operate as an overhead crane (which few factories can afford to buy or maintain), there remains significant risks for damage with this method as the enclosure must be dragged over what is often an uneven and/or broken surface.

Due to the above, cost/benefit ratios for decision-making often discourage factory personnel from moving the enclosure though movement might make the overall manufacturing process more efficient. Moving the enclosure down an assembly line or to the capital equipment that is fixed in its location, such as a paint booth, are simply two such examples of why an easier and less risky method for moving an enclosure would be ideal.

SUMMARY

Embodiments of the present invention relate generally to methods of constructing enclosures. More particularly, embodiments related generally to methods of constructing enclosures using embodiments of undercarriage support systems, as described generally herein.

In accordance with one embodiment, a method of constructing an enclosure using an undercarriage support system comprises: providing the undercarriage support system for supporting the enclosure during one or more stages of construction, the undercarriage support system comprising a plurality of modular enclosure support components and a plurality of motive supports for facilitating movement of the undercarriage support system; interconnecting ends of the modular enclosure support components via respective inter-component end ports, the inter-component end ports being positioned to facilitate modular interconnection of complementary modular enclosure support components and exhibiting a degree of structural rigidity sufficient to contribute to immobilization of interconnected modular enclosure support components relative to each other; assembling the interconnected modular enclosure support components such that the undercarriage support system exhibits a degree of structural rigidity sufficient to support an entire weight of the enclosure during one or more stages of construction, the undercarriage support system complementing a perimeter of a footprint of the enclosure; and executing one or more stages of enclosure construction while at least a portion of the enclosure is supported by the undercarriage support system and while the undercarriage support system and the enclosure supported thereon are moveable via the plurality of motive supports.

In accordance with another embodiment, a method of constructing an enclosure using an undercarriage support system comprises: providing the undercarriage support system for supporting the enclosure during one or more stages of construction, the undercarriage support system comprising a plurality of modular enclosure support components and a plurality of motive supports for facilitating movement of the undercarriage support system; interconnecting ends of the modular enclosure support components via respective inter-component end ports, the inter-component end ports being positioned to facilitate modular interconnection of complementary modular enclosure support components and exhibiting a degree of structural rigidity sufficient to contribute to immobilization of interconnected modular enclosure support components relative to each other; assembling the interconnected modular enclosure support components such that the undercarriage support system exhibits a degree of structural rigidity sufficient to support an entire weight of the enclosure during one or more stages of construction, the undercarriage support system complementing a perimeter of a footprint of the enclosure such that the interconnected modular enclosure support components define an interior construction space that permits movement of personnel within the perimeter of the footprint of the enclosure; stacking the modular enclosure support components so as to assemble of one or more layers of the interconnected modular enclosure support components to elevate the enclosure supported by the undercarriage support system; and executing one or more stages of enclosure construction while at least a portion of the enclosure is supported by the undercarriage support system and while the undercarriage support system and the enclosure supported thereon are moveable via the plurality of motive supports.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of specific embodiments can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

FIG. 1 is an illustration of a cross-sectional view of a modular enclosure support component according to one embodiment;

FIG. 2 is an illustration of a cross-sectional view of a modular enclosure support component and a motive support according to another embodiment;

FIG. 3 is an illustration of a top cross-sectional view of a plurality of interconnected modular enclosure support components according to another embodiment;

FIG. 4 is an illustration of a side cross-sectional view of a plurality of interconnected modular enclosure support components according to another embodiment;

FIG. 5 is an illustration of a top cross-sectional view of a plurality of interconnected modular enclosure support components according to another embodiment;

FIG. 6 is an illustration of a side cross-sectional view of a plurality of interconnected modular enclosure support components according to another embodiment;

FIG. 7 is an illustration of a side cross-sectional view of a plurality of interconnected modular enclosure support components and a protective layer according to another embodiment;

FIG. 8 is an illustration of a top view of a protective layer according to another embodiment;

FIG. 9 is an illustration of a view of an adaptor according to another embodiment;

FIG. 10 is an illustration of a side view of an undercarriage support system supporting an enclosure according to another embodiment; and

FIG. 11 is an illustration of a side view of an undercarriage support system supporting an enclosure according to another embodiment.

The embodiments set forth in the drawings are illustrative in nature and are not intended to be limiting of the embodiments defined by the claims. Moreover, individual aspects of the drawings and the embodiments will be more fully apparent and understood in view of the detailed description.

DETAILED DESCRIPTION

Embodiments of the present invention relate generally to methods of constructing enclosures using embodiments of undercarriage support systems, as described generally herein. The undercarriage support system may support enclosures of various dimensions, such as, but not limited to, temporary shelters, security enclosures, energy power modules, power modules, portable enclosures, etc.

Referring initially to FIG. 10, the undercarriage support system 14 is provided for supporting the enclosure 12 during one or more stages of construction of the enclosure 12. The undercarriage support system 14 comprises a plurality of modular enclosure support components 16 and a plurality of motive supports 18 for facilitating movement of the undercarriage support system 14 and an enclosure 12 supported thereon. As shown in FIGS. 3-7, the modular enclosure support components 16 are configured to interconnect so as to form a support for the enclosure 12. More particularly, the modular enclosure support components 16, shown in FIGS. 1 and 2, interconnect at ends 20 of the modular enclosure support components 16 via respective inter-component end ports 22 disposed at or near the ends 20 of the modular enclosure support components 16. As such, the inter-component end ports 22 are positioned to facilitate modular interconnection of the modular enclosure support components 16. Further, the modular enclosure support components 16 may be L-shaped or linearly shaped. When linearly shaped, the modular enclosure support components 16 may be configured to interconnect, via the inter-component end ports 22, in parallel to form a linear configuration of interconnected modular enclosure support components 16 or to interconnect angularly or perpendicularly to form an L-shaped or other angled configuration. It is contemplated that the modular enclosure support components 16 may be provided in one or more of any variety of dimensions, whether in width, length, height, or otherwise.

With variability in shapes and dimensions of the modular enclosure support components 16, the modular enclosure support components 16 may interconnect in configurations appropriate to support of any variety of differently sized and/or differently shaped enclosures. In addition, with the interconnecting of the modular enclosure support components 16 via the inter-component end ports 22, the interconnected modular enclosure support components 16 are assembled such that the undercarriage support system 14 exhibits a degree of structural rigidity sufficient to support an entire weight of the enclosure 12 during one or more stages of construction.

Further, the inter-component end ports 22 exhibit a degree of structural rigidity sufficient to contribute to immobilization of interconnected modular enclosure support components 16 relative to each other. In addition, the inter-component end ports 22 may permit disengagement of interconnected modular enclosure support components 16. As such, the undercarriage support system 14 may be partially or entirely disassembled to facilitate storage or shipment of the undercarriage support system 14. In addition, one or more of the modular enclosure support components 16 may be disengaged from other modular enclosure support components 16 for repair or replacement purposes should, for example, a modular enclosure support component 16 be damaged and/or the ability to support an enclosure 12 be compromised.

To further inhibit undesirable disengagement of interconnected modular enclosure support components 16, the inter-component end ports 22 may interlock. The interlocking of the inter-component end ports 22 may be achieved in one or more of any variety of ways, whether by insertable locking pins, retractable levers, or otherwise. The modular enclosure support components 16 may comprise one or more release mechanisms to control release of interlocked inter-component end ports 22 to permit disengagement of interconnected modular enclosure support components 16. The release mechanisms may be controllable manually at the modular enclosure support components 16, such as, with a manual withdrawal of a locking pin from inter-component end ports 22 or with actuation of a knob or button to disengage retractable levers from an interlocked state.

The inter-component end ports 22 may be configured in any manner sufficient to perform the purposes described herein of the inter-component end ports 22. In one exemplary embodiment, shown in FIGS. 2 and 3, the inter-component end ports 22 are configured as complementary pins 24 and recesses 26. In another exemplary embodiment, the inter-component end ports 22 are configured as complementary tongue and groove connectors. In another exemplary embodiment, the inter-component end ports 22 are configured as complementary dovetail connectors. In yet another exemplary embodiment, the inter-component ports 22 are configured as a combination of any of the above and/or other interconnectable ports.

With the assembling of the modular enclosure support components 16 via the inter-component end ports 22, the undercarriage support system 14 complements a perimeter of a footprint of the enclosure 12 to be supported during one or more stages of construction. More particularly, the interconnected modular enclosure support components 16 define an interior construction space that permits movement of personnel within the perimeter of the footprint of the enclosure 12. This interior construction space may facilitate execution of one or more stages of construction of an enclosure 12 at least partially supported by the undercarriage support system 14.

To further facilitate execution of one or more stages of enclosure construction, the enclosure 12 may be elevated with respect to a ground surface, which may improve the ergonomics associated with constructing the enclosure 12. More particularly, the modular enclosure support components 16 may be configured to stack so as to permit assembling of two or more layers of interconnected modular enclosure support components 16. Thereby, the layers of interconnected modular enclosure support components further elevate the enclosure 12 with respect to a ground surface. Alternatively, or in addition thereto, the undercarriage support system 14 may further comprise a plurality of stacking blocks 30, as shown in FIG. 11. The stacking blocks 30 may be configured to stack on top of each other and/or on top surfaces of the interconnected modular enclosure support components 16 so as to form two or more layers 28 formed through a combination of modular enclosure support components and stacking blocks 30. Thereby, the stacking blocks 30 further elevate the enclosure 12 with respect to a ground surface. In addition, it is contemplated that a combination of two or more layers of stacked, interconnected modular enclosure support components 16 and one or more layers of stacking blocks 30 may be assembled to further elevate the enclosure 12 with respect to a ground surface.

As shown in FIG. 11, stacked layers 28 of modular enclosure support components 16 and/or stacking blocks 30 may be secured so as to prevent lateral movement between the stacked layers 28. This securing of the stacked layers 28 may be achieved through one or more of any variety of interconnecting devices. For example, but not by way of limitation, FIG. 11 illustrates U-bolts 31 inserted into stacked layers 28 of modular enclosure support components 16 and stacking blocks 30 and pins 33 inserted between stacked layers 28 of stacking blocks 30. It is also contemplated that the modular enclosure support components 16 and/or stacking blocks 30 may comprise coupling ports configured and positioned to facilitate vertical interconnection, through stacking, of the modular enclosure support components 16 and/or stacking blocks 30 to sufficiently secure the stacked layers 28 to prevent lateral movement there-between.

As shown in FIGS. 7, 8, 10, and 11, the undercarriage support system 12 also may comprise a protective layer 32 that is configured to protect portions of the enclosure 12 in direct contact with the undercarriage support system 14 from marring or other damage. As such, as shown in FIGS. 10 and 11, the protective layer 32 generally is applied to top surfaces of a top layer of modular enclosure support components 16 or to top surfaces of a top layer of stacking blocks 30 to protect what is generally a bottom surface of the perimeter of the enclosure 12. The protective layer 32 may be configured of any material suitable for performing the purposes described herein. For example, but not of limitation, the protective layer 32 may be configured of Delrin®. As shown in FIGS. 7 and 8, the protective layer 32 may be applied to the modular enclosure support components 16 and/or the stacking blocks 30 by one or more fasteners 34, such as, but not limited to, screws or bolts, through one or more apertures 36 in the protective layer 32. To prevent marring or other damage to the enclosure 12, the apertures 36 may be configured to permit the countersinking of the fasteners 34 such that the fasteners 34 do not project above a top surface of the protective layer 32. It is contemplated that the protective layer 32 may be applied to the modular enclosure support components 16 and/or the stacking blocks 30 by other or additional applications.

As mentioned above, the undercarriage support system 14 also comprises a plurality of motive supports 18 for facilitating movement of the undercarriage support system 14 and any enclosure 12 supported thereon. Generally, the motive supports 14 are positioned on bottom surfaces 38 of one or more of the modular enclosure support components 16. One or more of any variety of motive supports suitable for use as described herein may be used. In one exemplary embodiment, shown in FIGS. 2, 4, 6, 7, 10, and 11, the motive supports 14 are casters 18. These casters of the undercarriage support system 14 may be swivel casters or rigid casters, or a combination thereof. The swivel casters or the rigid casters, or both, may be lockable so as to prevent undesired movement of the undercarriage support system 14. Further, it is contemplated that the weight capacity of the undercarriage support system 14 is scalable by interchanging casters, or other motive supports 18, with those with greater weight-bearing capacity.

In addition, the swivel casters or the rigid casters, or both, may be adjustable in height so as to adjust an elevation between the bottom surfaces 38 of the interconnected modular enclosure support components 16 and a ground surface. This height adjustability of the casters may be provided suitable mechanisms, such as, but not limited to, spring-loaded locks or snap-fit locks. Further, the swivel casters or the rigid casters, or both, respectfully comprise a suspension to facilitate movement of the undercarriage support system 14, particularly over uneven surfaces. Using casters, or other motive supports 18, with suspensions, the elevation of the enclosure 12 with respect to a ground surface can remain relatively constant though the ground surface may be uneven. Thus, the suspension may help maintain the structural integrity of the enclosure 12 being built. The suspension may be configured as pneumatic cylinders or springs, or otherwise.

To further facilitate movement of the undercarriage support system 14 and any enclosure 12 supported thereon, the undercarriage support system may comprise an adaptor 40, as shown in FIG. 9. The adaptor 40 may be configured to couple to one or more of the interconnected modular enclosure support components 16 or to one or more of the motive supports 18, or both, to facilitate movement of the undercarriage support system 14. More particularly, one or more of the modular enclosure support components 16 or one or more of the motive supports 18, or both, may comprise one or more receivers 46, shown in FIG. 11, that are configured to couple to one or more coupling devices 44, shown in FIG. 9, of the adaptor 40. Further, the adaptor 40 may further comprise an eyelet 42 configured to couple to a device configured to move the undercarriage support system 14 and any enclosure 12 supported thereon via the adaptor 40. For exemplary purposes only, the adaptor 40 may couple to a forklift or other motorized vehicle that may tow, pull, or otherwise move the undercarriage support system 14 and any enclosure 12 supported thereon via the adaptor 40. Thereby, one or more stages of enclosure construction may be executed while at least a portion of the enclosure 12 is supported and moveable by the undercarriage support system 14 via the plurality of motive supports 18 and, if used, an adaptor 40. The ability to move an enclosure 12 during its construction may improve the overall efficiency of the enclosure construction process as the enclosure 12 may now move to different equipment or process stages without requiring any necessary machinery or equipment to come to what would otherwise be a fixed location of the enclosure 12.

It is noted that recitations herein of a component of an embodiment being “configured” in a particular way or to embody a particular property, or function in a particular manner, are structural recitations as opposed to recitations of intended use. More specifically, the references herein to the manner in which a component is “configured” denotes an existing physical condition of the component and, as such, is to be taken as a definite recitation of the structural characteristics of the component.

It is noted that terms like “generally” and “typically,” when utilized herein, are not utilized to limit the scope of the claimed embodiments or to imply that certain features are critical, essential, or even important to the structure or function of the claimed embodiments. Rather, these terms are merely intended to identify particular aspects of an embodiment or to emphasize alternative or additional features that may or may not be utilized in a particular embodiment.

For the purposes of describing and defining embodiments herein it is noted that the terms “substantially” and “approximately” are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms “substantially” and “approximately” are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

Having described embodiments of the present invention in detail, and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the embodiments defined in the appended claims. More specifically, although some aspects of embodiments of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the embodiments of the present invention are not necessarily limited to these preferred aspects. 

1. A method of constructing an enclosure using an undercarriage support system, the method comprising: providing the undercarriage support system for supporting the enclosure during one or more stages of construction, the undercarriage support system comprising a plurality of modular enclosure support components and a plurality of motive supports for facilitating movement of the undercarriage support system; interconnecting ends of the modular enclosure support components via respective inter-component end ports, the inter-component end ports being positioned to facilitate modular interconnection of complementary modular enclosure support components and exhibiting a degree of structural rigidity sufficient to contribute to immobilization of interconnected modular enclosure support components relative to each other; assembling the interconnected modular enclosure support components such that the undercarriage support system exhibits a degree of structural rigidity sufficient to support an entire weight of the enclosure during one or more stages of construction, the undercarriage support system complementing a perimeter of a footprint of the enclosure; and executing one or more stages of enclosure construction while at least a portion of the enclosure is supported by the undercarriage support system and while the undercarriage support system and the enclosure supported thereon are moveable via the plurality of motive supports.
 2. The method of claim 1, wherein the interconnected modular enclosure support components define an interior construction space that permits movement of personnel within the perimeter of the footprint of the enclosure.
 3. The method of claim 1, wherein the modular enclosure support components are configured to stack so as to permit assembling of two or more layers of interconnected modular enclosure support components to elevate the enclosure supported by the undercarriage support system.
 4. The method of claim 3, wherein a protective surface is applied to at least a portion of a top surface of the interconnected modular enclosure support components forming a top layer of stacked interconnected modular enclosure support components.
 5. The method of claim 1, wherein a protective surface is applied to at least a portion of a top surface of the interconnected modular enclosure support components.
 6. The method of claim 1, wherein the inter-component end ports permit disengagement of interconnected modular enclosure support components.
 7. The method of claim 1, wherein the inter-component end ports interlock to inhibit disengagement of interconnected modular enclosure support components.
 8. The method of claim 1, wherein the modular enclosure support components further comprise one or more release mechanisms to control release of interlocked inter-component end ports to permit disengagement of interconnected modular enclosure support components.
 9. The method of claim 1, wherein the undercarriage support system further comprises a plurality of stacking blocks configured to stack on top surfaces of the interconnected modular enclosure support components so as to elevate the enclosure supported by the undercarriage support system.
 10. The method of claim 1, wherein a protective surface is applied to one or more of the top surfaces of the stacking blocks forming a top layer of stacked stacking blocks.
 11. The method of claim 1, wherein: the inter-component end ports are configured as complementary pins and recesses, the inter-component end ports are configured as complementary tongue and groove connectors, or the inter-component end ports are configured as complementary dovetail connectors, or combinations thereof.
 12. The method of claim 1, wherein the plurality of motive supports are positioned on bottom surfaces of one or more of the modular enclosure support components of the undercarriage support system.
 13. The method of claim 1, wherein the motive supports are swivel casters or rigid casters, or a combination thereof.
 14. The method of claim 13, wherein the swivel casters or the rigid casters, or both, are lockable so as to prevent undesired movement of the undercarriage support system.
 15. The method of claim 13, wherein the swivel casters or the rigid casters, or both, are adjustable in height to as to adjust an elevation of a bottom surface of the interconnected modular enclosure support components from a ground surface.
 16. The method of claim 13, wherein one or more of the swivel casters or one or more of the rigid casters, or both, respectfully comprise a suspension to facilitate movement of the undercarriage support system.
 17. The method of claim 1, wherein the undercarriage support system further comprises an adaptor configured to couple to one or more of the interconnected modular enclosure support components or one or more of the motive supports, or both, to facilitate movement of the undercarriage support system.
 18. The method of claim 17, wherein one or more of the interconnected modular enclosure support components or one or more of the motive supports, or both, comprise one or more receivers configured to couple to the adaptor.
 19. The method of claim 17, wherein the adaptor comprises an eyelet configured to couple to a device configured to move the undercarriage support system via the adaptor.
 20. A method of constructing an enclosure using an undercarriage support system, the method comprising: providing the undercarriage support system for supporting the enclosure during one or more stages of construction, the undercarriage support system comprising a plurality of modular enclosure support components and a plurality of motive supports for facilitating movement of the undercarriage support system; interconnecting ends of the modular enclosure support components via respective inter-component end ports, the inter-component end ports being positioned to facilitate modular interconnection of complementary modular enclosure support components and exhibiting a degree of structural rigidity sufficient to contribute to immobilization of interconnected modular enclosure support components relative to each other; assembling the interconnected modular enclosure support components such that the undercarriage support system exhibits a degree of structural rigidity sufficient to support an entire weight of the enclosure during one or more stages of construction, the undercarriage support system complementing a perimeter of a footprint of the enclosure such that the interconnected modular enclosure support components define an interior construction space that permits movement of personnel within the perimeter of the footprint of the enclosure; stacking the modular enclosure support components so as to assemble of one or more layers of the interconnected modular enclosure support components to elevate the enclosure supported by the undercarriage support system; and executing one or more stages of enclosure construction while at least a portion of the enclosure is supported by the undercarriage support system and while the undercarriage support system and the enclosure supported thereon are moveable via the plurality of motive supports. 